Method and system for radio-frequency signal coupling to medium tension power lines with auto-tuning device

ABSTRACT

In one aspect, the present invention comprises a method for tuning a power line communication inductive signal coupling device comprising a coupler and a plurality of capacitors, the method comprising: passing a carrier frequency signal through the coupler; sensing an amplitude of the signal; and switching the capacitors until the amplitude of the signal reaches a maximum. In various embodiments: (a) the signal is transmitted by a second transmitter, and the method further comprises switching to a first transmitter for data transmission; (b) the signal is received by a receiver after passing through the coupler; and (c) the capacitors are switched by a relay controller receiving commands from a microprocessor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/198,795, filed Aug. 4, 2005, which claims the benefit of U.S.Provisional Patent Application No. 60/598,783, filed Aug. 4, 2004, andof U.S. Provisional Patent Application No. 60/667,106, filed Mar. 31,2005. The entire contents of each of these applications are incorporatedherein by reference.

BACKGROUND

Medium tension lines carry electricity for distribution to end users.Such lines typically carry potential of 4 kilovolts to 33 kilovolts,measured phase to phase. They typically are configured as single phaseand neutral, three phases without neutral, or three phases with neutral,although other combinations exist. The distribution line is often aerialuntil it gets close to homes or urban areas, where it often is convertedto underground distribution. Underground medium tension cables areusually coaxial single phase cables. These cables have a coaxial,insulated shield that carries neutral current and protects againstbuildup of electric fields, which would be dangerous to the touch.Properly connected underground cables are safe to touch withoutinsulated gloves or other protection.

Where the underground cables connect to the aerial cables, special careis taken at the junction. Aerial cables often are bare (not insulated)or covered only with weather-proof sheathing. Underground cables havemulti-layer insulation between the phase conductor in the center and thecoaxial neutral shield, which is covered by an insulating layer on theoutside. To prevent an electric arc from running down the outside of thecable, a “stress cone” is connected to the end of the underground cable.The coaxial neutral shield is peeled back where it meets the stress coneand is connected to ground.

Medium tension lines emanate from a substation where there is atransformation from transmission voltage (typically 60-150 kilovolts)down to the appropriate medium tension voltage level. Trunk distributionlines radiate from the substation, and branch distribution lines emanatefrom the trunk lines.

SUMMARY

The method of the current invention is to couple a radio-frequencysignal to either underground or aerial electrical distribution cablesand automatically tune the signal coupler to highest efficiency(maximize the signal-to-noise ratio) as the current on the distributionline varies.

In one aspect, the present invention comprises a method for tuning apower line communication inductive signal coupling device comprising acoupler and a plurality of capacitors, the method comprising: passing acarrier frequency signal through the coupler; sensing an amplitude ofthe signal; and switching the capacitors until the amplitude of thesignal reaches a maximum.

In various embodiments: (a) the signal is transmitted by a secondtransmitter, and the method further comprises switching to a firsttransmitter for data transmission; (b) the signal is received by areceiver after passing through the coupler; and (c) the capacitors areswitched by a relay controller receiving commands from a microprocessor.

In another aspect, the invention comprises a system for power linecommunication, comprising: a transmitter operable to transmit a signalat a desired frequency; an inductive coupler in communication with thetransmitter; a receiver operable to receive signals passed through thecoupler; a microprocessor in communication with the receiver; a relaycontroller in communication with the microprocessor; and a plurality ofcapacitors; wherein the controller is operable to switch the capacitorspursuant to commands received from the microprocessor, and wherein themicroprocessor is operable to analyze amplitudes of signals transmittedby the transmitter through the coupler and received by the receiver, andfurther operable to send commands to the relay controller to switch thecapacitors until the amplitudes are maximized.

In another aspect, the invention comprises a system for power linecommunication comprising an inductive coupler configured to replace adrop wire from a feeder line to a lateral line.

In a further aspect, the invention comprises a method for power linecommunication, comprising: identifying a drop wire between a feeder lineand a lateral line; and replacing the drop wire with an inductivecoupler. In one embodiment, the coupler is operable to performauto-tuning.

In another aspect, the invention comprises a method for power linecommunication, comprising: identifying a drop wire from a feeder line toa bank of power factor correction capacitors; and replacing the dropwire with an in-line inductive coupler. In one embodiment, the coupleris an auto-tuning coupler

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a preferred embodiment of the invention.

FIG. 2 provides a table showing that maximum impedance provides formaximum signal coupling efficiency.

FIG. 3 is a schematic diagram depicting preferred construction of anauto-tuning box.

FIG. 4 is a diagram depicting preferred installation of a ScanTransponder-5 at a branch circuit using a coupling optimizer.

FIG. 5 depicts on-site installation of a preferred inductive signalcoupler.

FIG. 6 depicts on site installation as shown in FIG. 5, but also depicts(see insert) an alternative installation.

FIG. 7 is an enlargement of the capacitors depicted in FIG. 1.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The apparatus preferably is installed and the signal coupler mounted onthe distribution cable at the point where a branch line begins. This hasthe effect of maximizing the signal in the branch line as the lowimpedance of the trunk line provides a return path for the current. Italso has the effect of partially isolating the branch line from thetrunk line, as the coupler has a series impedance at the signalfrequency (approximately 15-95 kHz) which is higher than the impedanceon the trunk line.

To automatically vary the impedance of the coupler, the method in theblock diagram of FIG. 1 preferably is used. The coupler has 16 turns ofwire that is used to form a parallel tank circuit with selectableexternal capacitors. The medium tension insulated power distributionline passes through the center of the coupler. Two transmit signal wirespass through the coupler; one carries a carrier signal at the selectedfrequency, while the other carries the modulated data signal at the samefrequency.

Transmitter #2 is turned on at the desired frequency, passing thecarrier frequency signal through a 250-ohm resistor and the coupler. Thereceiver is connected to the same circuit and is used to sense theamplitude of the signal at the coupler. The microprocessor sends MODBUSprotocol commands to the DI-509 controller to control the relays, whichswitch capacitors in and out of the circuit until the maximum signal isreceived at the coupler. This causes the coupler to be tuned to themaximum impedance for the selected frequency. Maximum impedance isdesirable because it provides for maximum signal coupling efficiency, asshown in the table in FIG. 2.

When the auto-tune sequence is completed and maximum signal coupling(highest signal-to-noise ratio) is achieved, Transmitter #1 is then usedfor data transmission.

In one preferred embodiment, the coupler is mounted to a section ofcable (e.g., two meters long or so) and then surrounded byweather-resistant material (e.g., plastic molding). This improvesdurability and enhances installation.

The invention has numerous advantages over the prior art that will beapparent to those skilled in the art. For example, as discussed above,because of the relative impedance of the trunk line being low and thatof a branch being somewhat higher, the coupler tends to isolate thesignals that are on the branch from the coupler, preventing them frombeing sucked into the branch. So it gives it a higher impedance forsending the signals out and receiving them back. They have to passthrough the coupler before they go into the trunk line, so that thecoupler tends to capture the signal (as a receiver). For transmission,having a lower impedance behind the coupler is good for sending signalsdown the branch.

Another advantage is ease of installation, which often entails merelyreplacing a pre-existing section of cable (a “loop”) used to couple atrunk line to a branch with the cable-mounted coupler of the invention.

An advantage of auto-tuning is that it enables not only re-tuning asneeded to compensate for temperature changes, but it also enablesre-tuning due to signal frequency changes. Preferably several differentfrequencies are used (e.g., 16), to reduce interference problems or toenable different frequencies to be used on adjacent branch lines.

In an alternate embodiment, the coupler is fitted or in communicationwith a temperature sensor, to enable re-tuning as a consequence oftemperature values (or temperature change values). In anotherembodiment, the coupler is fitted or in communication with a frequencydetector, to enable re-tuning as a consequence of a frequency change. Infurther embodiments, when temperature or frequency changes are detected,total re-tuning does not necessarily occur. Instead, the coupler istuned to the state that was used previously when that frequency ortemperature was detected. This reduces the number of re-tuningsrequired. Frequent re-tunings can be problematic when, for example,frequencies are changed often.

Coupling to the point where a branch (or lateral) feeder splits off fromthe trunk (or express) feeder is best employed (for economic reasons)where there are more than 50-75 customers on the lateral feeder to whichthe coupler is connected. A coupler typically is installed together witha Transponder (a bidirectional communications device for powerlinecommunications sold by Quadlogic Controls Corp of New York, N.Y., USA(“QLC”)). The total cost of the coupler plus the Transponder meritscareful planning of the deployment of the coupler/Transponder sites.

The automatic tuning coupler can be used in additional situations:

-   -   1) On the main feeder by adding high voltage blocking capacitors        (for example metallized polyester 0.25 microfarad 12 kilovolt AC        capacitors or commercially available oil filled power factor        correction type capacitors). To use this method, install a dual        bushing capacitor on a utility pole. Connect one bushing to a 12        kV phase line, connect the other bushing to an adjacent phase        line or neutral via the coupler described previously. This        places the coupler in series with the capacitor. This can be        accomplished using a commercially available 10 k VAR capacitor        with dual bushing from a manufacturer such as ABB (Asea Brown        Bovari).    -   2) Wherever there are banks of power factor correction        capacitors already installed before the coupler is installed, a        coupler should be installed on the existing capacitor bank.        Existing capacitor banks are installed on the trunk or other        feeders for the purpose of correction of power factor. These        capacitor banks most likely use capacitors such as the one        described in the previous point. The end result of this is the        same as the point 1 above. The coupler ends up in series with a        capacitor, connected either phase to phase or phase to neutral.        The only difference is whether the capacitor bank was existing        before the coupler was installed or whether it was installed as        part of the coupler installation.

Transponder/Coupler Placement and Selection

Transponder/Coupler Placement: The main factors influencing the locationof a Transponder/Coupler are the number of laterals (branches) and thenumber of clients per lateral. If there are enough meters on a lateralto warrant the installation of a Transponder/Coupler, theTransponder/Coupler should be located on that lateral.

Some general rules of thumb are:

-   -   1. Maximum number of meters per Transponder/Coupler location—200    -   2. Signal can pass through:        -   a. One transformer        -   b. Three branches (e.g. Express to lateral to sublateral OR            Lateral to sublateral to sub-sublateral)        -   c. Upwards of 15 km (Field proven at 15 km) of express line    -   3. Minimum number of couplers per Transponder/Coupler:        -   a. 3 ph. 3 W.—1 coupler        -   b. 3 ph. 4 W. 3 couplers        -   c. Single phase loads—1 coupler per phase

Signal Coupling Unit (SCU) Deployment Options:

-   -   1. Inline lateral coupler:    -   This unit replaces the drop wire from the feeder to the lateral.        This coupler should be used on laterals which have large numbers        of customers (greater than 75.)    -   2. Express Feeder Coupler:    -   This unit is installed directly on the express feeder with the        addition of a 10KVAR 12 kilovolt dual bushing capacitor (ABB        manufactures capacitors for this application). It can be        installed either phase to phase or phase to neutral. This is        useful on long express feeders with laterals having few        customers (up to 200 or 15 km of express line length.)    -   3. Capacitive couplers:    -   Similar to the inline lateral coupler, this unit replaces the        drop wire from the feeder to an existing bank of power factor        correction capacitors. It must be used wherever there is a        capacitor bank installed on any feeder—either express (trunk) or        lateral (branch) feeder.    -   4. Split core couplers:    -   These units are designed for underground, insulated cables and        should be deployed wherever there are power factor correction        capacitors. Typically these units would be used for suburban        subdivisions with underground distribution.

Conservative Design Notes:

-   -   1. A Transponder/Coupler must be installed wherever there are        power factor correction capacitors.    -   2. A Transponder/Coupler-200 has a maximum capacity of 200        customers. (Except in cases of densely populated laterals, for        example of 75-100 customers where one Transponder/Coupler would        be installed for this subset of customers.)    -   3. For every 15 km of express line length, a Transponder/Coupler        likely will be required.    -   4. A Transponder/Coupler is expected to traverse no more than 3        branches (e.g., express to lateral to sublateral, or lateral to        sublateral to sub-sublateral).    -   5. No customer data can be transmitted through more than one        transformer to the Transponder/Coupler (this is very rare).    -   6. A coupler can serve as a block for a neighboring        Transponder/Coupler to bypass a lateral and communicate with        meters beyond that coupler. For example, Transponder/Coupler “A”        communicates to a geographic area of 15 lightly populated        laterals. Within that area, there is one densely populated        lateral (75-100 customers) that requires Transponder/Coupler B.        Transponder/Coupler B will not permit Transponder/Coupler A's        PLC signal to run down its lateral (“PLC” is power line        communication). Therefore, Transponder/Coupler B allows        Transponder/Coupler A to essentially ignore the densely        populated lateral and bypass it to communicate with the        remaining lightly populated laterals down the line.    -   7. By careful engineering of each system, as each system is        unique, utilizing the different coupling systems, it is possible        to optimize communication integrity with a minimum of        transponder/coupler sets, thus reducing reliance on costly,        monthly fees from third party suppliers.    -   8. Coupler designs are available up to 35 kV, and all are for        indoor or outdoor use on copper or aluminum.

SCU Utilization: The overhead couplers are designed to allow installinstallation using live line techniques when used on lateral feeds orexpress feeders. This means that the couplers can be installed withoutdisconnecting power. See FIGS. 5 and 6. The split core may be installedthis way on underground installations where the concentric neutral isstripped back or nonexistent.

The coupler will also act as an upstream block to down stream signalsmaking it a useful tool in PLC communication design. As more than onecoupler can be tied to a Transponder/Coupler they can be used tocross-communicate between two different laterals, in close proximity.

Transponder: The transponder module has the ability to handlebi-directional requirements for up to 200 metering units, and up tothree modules can be ganged together to make a transponder unit that canservice 600 metering units via PLC. The transponder unit has the abilityto output to a variety of communication media (all via existing RS232,RS485, or POTS plain-old telephone modem):

-   -   1. GPRS    -   2. POTS Telephone copper pair via internal modem (19200 Baud)    -   3. CDMA/GSM    -   4. RS 232    -   5. RS 485    -   6. Fiber (via fiber to RS232 converter)    -   7. PLC to master transponder via power lines

The system has the ability to transmit on several frequencies and tohave the communication timing planned and programmed so that largesystems can be engineered to avoid communications and data collisionissues.

The transponder, in one embodiment, requires 3 phase power supply @ 60Hz.

PLC Frequencies: When multiple Transponders are installed on one feeder,the Transponders will utilize the “channel groups” feature so as not tointerfere with each other. The transponders are put on differentfrequencies. QLC's PLC has five bands each with 16 frequencies totaling80 channels.

32 channels are used for medium to low tension communication

32 channels are used for medium to medium tension communication

16 channels are used for low to low tension communication

=80 channels total

Each channel can collect daily metering information for 200 customerswithin the allotted time to perform this task.

PLC Bandwidth: The QLC System operates at a high enough bandwidth toallow the collection of interval data from large meter populations. EachTransponder module is able to collect 200 meters programmed with hourlyinterval data within a 5 hour time frame so as to have data availablefor collection by 5 AM.

Although those skilled in the art will understand, from the abovedescription, how to make and use the claimed invention, additionaldetails regarding construction of a preferred embodiment are providedbelow.

Construction of Signal Couplers for 150 Amp Application

Ferrite Brick:

Required Materials:

10 U-shaped ferrites—(Magnetics 49925 F)

20—0.50″ segments of 1.5″ diameter heat shrink tubing (3M: CP221)

8—0.25″ segments of 1.5″ diameter heat shrink tubing (3M: CP221)

20—7″ zip ties (Gardner Bender: 46-308)

22—11″ zip ties (Gardner Bender: 46-310)

10 spacers—Incompressible plastic 0.375″×0.375″×0.016″

Krazy glue

60 feet 18 AWG Hook-up Wire (Alpha Brand UL1015)

Construction Procedure:

Place two 0.50″ segments as sleeves over each prong of the U-shapedferrite. Slide both segments all the way to the bottom of the U. Heatshrink the segment to create a snug sleeve. Wrap two 7″ zip ties on thebottom side of each sleeve and tighten to secure each sleeve fromsliding. Repeat the process to create 10 pieces.

Stack 5 U-pieces together in parallel. Sandwich a 0.25″ flattenedsegment at each of the four surfaces where the troughs of the U's meet.Fasten two 11″ zip-ties together, head to tail to make one double lengthzip tie. Use this “double-tie” to hold the U's together at the troughs.Make two more double-ties to hold the U's together at each prong of theU's. Repeat this process with the remaining 5 U-pieces to make anotherstack.

Designate one stack as the “bottom stack” and the other as the “topstack.” On the bottom stack, glue 10 spacers, one on the surface of eachend of each U. Allow glue to dry.

Mate the two stacks together to create a closed rectangular block. Thesurface-ends of the U's should meet, creating a stack of 5-parallelrectangular frames. Create 5 more double-ties. Secure each of the fiverectangular frames under tension with a double-tie.

Feed 16 turns of 14 AWG wire over the top stack and leave excess lengthof 20 feet on both sides. Twist the excess wire to create a twistedpair.

Auto-Tuning Box

Required Materials:

Plastic Enclosure

Circuit Board

High voltage High-Q capacitors

2—0.15 nF 1 KV Ceramic (Panasonic: ECC-D3A151JGE)

2—0.27 nF 1 KV Ceramic (Panasonic: ECC-D3A271JGE)

2—0.47 nF 1 KV Ceramic (Panasonic: ECC-D3A471 JGE)

2—1.0 nF 630V Polypropylene (Panasonic: ECQ-P6102JU)

2—2.2 nF 630V Polypropylene (Panasonic: ECQ-P6222JU)

2—3.9 nF 630V Polypropylene (Panasonic: ECQ-P6392JU)

2—8.2 nF 630V Polypropylene (Panasonic: ECQ-P6822JU)

2—15 nF 630V Polypropylene (Panasonic: ECQ-P6153JU)

2—27 nF 630V Polypropylene (Panasonic: ECQ-P6273JU)

2—47 nF 630V Polypropylene (Panasonic: ECQ-P6473JU)

20—Relay Reed SPST 12VDC (US Relays and Technology, Inc.: P1A12A)

1—Connector Terminal Block 4 position 5.08 mM PCB (Phoenix Contact:1729144)

2—18″ 22AWG UL2464 12 Conductor (general Cable/Carol Brand: C4067-12-10)

1—Breadboard 2.73×17″ (Keystone Electronics: 3407)

Construction: See FIG. 1 and FIG. 3.

While certain specific embodiments of the invention have been describedherein for illustrative purposes, the invention is not limited to thespecific details, representative devices, and illustrative examplesshown and described herein. Various modifications may be made withoutdeparting from the spirit or scope of the invention defined by theappended claims and their equivalents.

1. A method for dynamically tuning a power line communication systemcomprising an inductive coupler, a tank circuit comprising a pluralityof capacitors, a first transmitter, and a receiver, said methodcomprising: installing said inductive coupler without a power outage;passing a first selected carrier frequency signal generated by saidfirst transmitter through said coupler; receiving said first selectedcarrier frequency signal at said receiver; measuring amplitude of saidreceived first selected carrier frequency signal; switching saidcapacitors in and out of said tank circuit until said measured amplitudeof said received first selected carrier frequency signal is at amaximum; passing a second selected carrier frequency signal generated bysaid first transmitter through said coupler; receiving said secondselected carrier frequency signal at said receiver; measuring amplitudeof said received second selected carrier frequency signal; and switchingsaid capacitors in and out of said tank circuit until said measuredamplitude of said received second selected carrier frequency signal isat a maximum; wherein said second selected carrier frequency signal isdifferent from said first selected carrier frequency signal.
 2. A methodas in claim 1, further comprising switching to a second transmitter fordata transmission.
 3. A method as in claim 1, wherein said plurality ofcapacitors are switched by a relay controller receiving commands from amicroprocessor.
 4. A method as in claim 1, wherein said step of passingsaid second selected carrier frequency signal generated by saidtransmitter through said coupler is performed in response to one or morechanges in power line conditions.
 5. A method as in claim 1, whereinsaid step of passing said second selected carrier frequency signalgenerated by said transmitter through said coupler is performed inresponse to one or more changes in temperature.
 6. A method as in claim1, wherein said step of passing said second selected carrier frequencysignal generated by said transmitter through said coupler is performedin response to one or more changes in frequency of said first selectedcarrier frequency signal.
 7. A method as in claim 1, wherein said stepof passing said second selected carrier frequency signal generated bysaid transmitter through said coupler is performed in response to one ormore changes in signal-to-noise ratio on a power line.
 8. A method as inclaim 1, wherein said tank circuit is a parallel circuit in series witha power line.
 9. A method as in claim 1, wherein said step of installingsaid coupler without a power outage comprises: installing said inductivecoupler on an insulated medium tension rated cable section; installingsaid insulated medium tension rated cable section with inductive couplerinstalled in parallel with a section of distribution cable; removingsaid section of distribution cable, thereby making a distribution cableline frequency current pass through said inductive coupler; establishingcommunication between said inductive coupler and said transmitter andreceiver; establishing communication between said inductive coupler anda relay controller in communication with a microprocessor incommunication with said plurality of capacitors; and establishingcommunication between said inductive coupler and said plurality ofcapacitors in communication with said microprocessor.
 10. A method ofinstalling an inductive coupler, comprising: installing said inductivecoupler on an insulated medium tension rated cable section; installingsaid insulated medium tension rated cable section with inductive couplerinstalled in parallel with a section of distribution cable; removingsaid section of distribution cable, thereby making a distribution cableline frequency current pass through said inductive coupler; establishingcommunication between said inductive coupler and a transmitter andreceiver; establishing communication between said inductive coupler anda relay controller in communication with a microprocessor incommunication with a plurality of capacitors; and establishingcommunication between said inductive coupler and said plurality ofcapacitors in communication with said microprocessor.